E-raamat: Friction Stir Welding and Processing: Fundamentals to Advancements

Preface xx

Acknowledgements xx

About the Editors xx

List of Contributors xx

List of Figures xx

List of Tables xiii

Chapter 1: Introduction to Friction Stir Welding
Farooz Najar Ahmad, Shazman Nabi, Sandeep Rathee, Manu Srivastava

1.1 Introduction

1.2 FSW setup and working principle

1.3 Weld Zones

1.4 Variants of FSW

1.5 Defects

1.6 Advantages and limitations of FSW

1.7 Conclusion and future prospectus

Chapter 2: Friction Stir Welding and Single Point Incremental Forming: State-of-the-Art
H. D. Mhatre, A. S. Mulay, V. S. Gadakh

2.1 Introduction

2.2 Friction stir welding (FSW)

2.3 Single Point Incremental Forming (SPIF):

2.4 FSW and SPIF

2.5 Summary and outlook

Chapter 3: Friction stir brazing and friction stir vibration brazing
Behrouz Bagheri, Mahmoud Abbasi

3.1 Introduction to FSB

3.2 Variants of FSB

3.3 Two Case studies

3.4 Application of FSB and its variants in industry

3.5 Summary and future directions

Chapter 4: Fundamentals of Friction Stir Processing
Atul Kumara, Devasri Fuloriaa, Manu Srivastava, Sandeep Rathee

4.1 Friction stir processing (FSP): Background

4.2 Working principle of FSP

4.3 Comparison with other SPD techniques

4.4 Process variables

4.5 Mechanisms of microstructural evolution during FSP

4.6 Critical issues in FSP

4.7 Future scope

Chapter 5: Role of FSP in surface engineering
Setu Suman, Kazi Sabiruddin

5.1 Introduction

5.2 Role of Surface Modification Techniques

5.3 Thermal Spray Technique

5.4. FSP - Solid State Coating Process

5.5 Process parameters of FSP: Surface engineering

5.6 Inappropriate characteristics of surface modification

5.7 Summary

Chapter 6: Surface composite fabrication using FSP
Baidehish Sahoo, Jinu Paul, and Abhishek Sharma

6.1 Introduction

6.2 Reinforcement incorporation approaches

6.3 Effect of process parameters

6.4 Microstructural evolution & mechanical properties

6.5 Strengthening mechanisms

6.6 Defects

6.7 Summary and Future directions

Chapter 7: Friction-stir welding of dissimilar metals
N. S. Khemnar, Y. R. Gunjal, V. S. Gadakh, A. S. Mulay

7.1 Introduction

7.2 Application areas of dissimilar material joining

7.3 Issues for dissimilar material joining

7.4 FSW of dissimilar materials

7.5 Recent developments in tool design and tool materials

7.6 Parameter Optimization

7.7 Common Defects occur in FSW of dissimilar metal joining

7.8 Future Recommendations for dissimilar metal joining

Chapter 8: Friction stir welding of aluminium and its alloys
P.Sivaprakasam, K.Deepak, D. Raja Joseph, Melaku Desta, Putti Venkata Siva Teja, M. Srinivasan

8.1 Introduction

8.2 Fundamentals of FSW

8.3 FSW of Aluminum and its alloy

8.4 Influences of process parameters

8.5 Testing and characterization of FSW of Al and its alloy

8.6 Additive mixed Friction Stir process of Al and its alloy

8.7 Applications

8.8 Conclusions

Chapter 9: Mechanical characterization of FSWed joints of dissimilar aluminum alloys of AA7050 and AA6082
Mohd Sajid, Gaurav Kumar, Husain Mehdi, Mukesh Kumar

9.1 Introduction

9.2 Materials and methods

9.3 Results and discussion

9.4 Conclusions

Chapter 10: Sample Preparation and Microstructural Characterization of Friction Stir Processed Surface Composites
Manu Srivastava, Sandeep Rathee, Shazman Nabi, Atul Kumar

10.1 Introduction

10.2 Sample preparation for microscopic analysis of metals, alloys and composites

10.3 Etching

10.4 Microstructural evolution

10.5 Conclusions

Chapter 11: Microstructural characterization and mechanical testing of FSWed/ FSPed samples
Prem Sagar, Sushma, M. Ashok kumar

11.1 Introduction

11.2 Microstructural characterization

11.3 Mechanical Testing

11.4 Conclusions

Chapter 12: Comparative Analysis of Microstructural and Mechanical Characteristics of Reinforced FSW Welds
Tanvir Singh

12.1 Introduction

12.2 Friction Stir Welding (FSW)

12.3 Reinforcing materials-based Fabrication of FSW Welds

12.4 Joinability of reinforced FSW welds

12.5 Metallurgical characteristics of FSW reinforced welds

12.6 Mechanical behavior of reinforced FSW welds

12.7 Conclusions

12.8 Future challenges

Chapter 13: Summary of efforts in manufacturing of sandwich sheets by various joining methods including solid-state joining method
Divya Sachan , R. Ganesh Narayanan and Arshad Noor Siddiquee

13.1 Introduction

13.2 Sandwich sheets

13.3 Classification of Sandwich sheet structures

13.4 Applications

13.5 Fabrication methods

13.6 Summary

Chapter 14: Defects in Friction Stir Welding and its Variant Processes
Vinayak Malik and Satish V. Kailas

14.1 Introduction

14.2 General Defects in FSW

14.3 Characteristic Defects in Friction Stir Butt and Lap Joints

14.4 Distinctive Defects in Major Friction Stir Variants

14.5 Solutions to avoid defects in Friction Stir based processes

14.6 Summary and concluding remarks

Chapter 15: Nondestructive ultrasonic inspections, evaluations, and monitoring in FSW / FSP
Yuqi Jin, Teng Yang, Narendra B. Dahotre, and Tianhao Wang

1. Ultrasonic wave behaviors in FSWed/FSPed samples

1.1. Influence from defects on ultrasound wave travelling

1.2. Influence from microstructures on ultrasound wave travelling

1.3. Influence from residual stresses on ultrasound wave travelling

2. Current ultrasonic inspection and evaluation methods for FSWed/FSPed samples

2.1. Ultrasound inspections on defects and flaws for FSWed/FSPed samples

2.2. Ultrasound evaluations on mechanical properties for FSWed/FSPed samples

2.3. Ultrasound monitoring for FSW/FSP

3. Case studies on recent novel ultrasound evaluation and monitoring in FSW / FSP

3.1. Ultrasonic elastographic evaluated dissimilar FSWed samples

3.2. Ultrasonic elastographic evaluated FSPed sample

3.3. Ultrasonic effective residual stress mapping on FSPed sample

3.4. Ultrasonic monitoring on FSW/FSP tool wearing

4. Roles and potentials of ultrasound in future FSW / FSP

Chapter 16: Applications of Friction Stir Welding
Raja Gunasekaran, Gobinath Velu Kaliyannan, K. Suganeswaran, N. Nithyavathy, S. Arun Kumar

16.1 Introduction

16.2 Application of FSW on Different Materials

16.3 Industrial applications of FSW

16.4 Conclusions

Chapter 17: Equipment used during FSP
Suganeswaran K, Nithyavathy N, Muthukumar P, Arunkumar S, Gobinath V. K

17.1 Introduction

17.2 FSP experimental setup

17.3 Microstructural characterization

17.4 Mechanical behaviour of composites based on various tool shapes

17.5 Mechanical behaviour of composites based on various process parameters

17.6 Conclusions

Chapter 18: Analysis of Friction Stir Welding Tool Using Various Threaded Pin Profiles: A Case Study
Bommana Boina Abhignya, Ashish Yadav, Manu Srivastava, Sandeep Rathee

18.1 Introduction

18.2 Geometry Considered

18.3 Results and Discussions - Analysis in ANSYS

18.4 Conclusion

References

Chapter 19: Static Structural and Thermal Analysis of Honeycomb Structure Fabricated by Friction Stir Process Route: A Case Study
Nikhil Jaiswal, Umashankar Bharti , Ashish Yadav, Manu Srivastava, Dr Sandeep Rathee

19.1. Introduction

19.2. Modelling

19.3. Result and Analysis

19.4. Scope of the study

19.5. Conclusion

Chapter 20: Friction Stir-based Additive Manufacturing
A. Gourav Rao and Neelam Meena

20.1 Additive Manufacturing: An Introduction

20.2 Solid-State AM processes

20.3 Case studies of FSAM on different materials

20.4 Advantages of FSAM over other AM techniques

20.5 Advancements

20.6 Limitations

20.7 Conclusions & Future prospectives

References